Predictive Maintenance Solution for AC Motors and Rotating Equipment

Unlike traditional solutions that use vibration sensors placed directly on the asset in the field, SAM4 measures electrical waveforms from inside the motor control cabinet.

Once installed, SAM4 monitors 24/7, detects well over 90% of failures up to five months in advance and alerts users of upcoming failures, so they can prevent unplanned downtime by scheduling inspections, repairs or replacements before equipment fails.

Able to generate insights that reduce energy waste by as much as 20% through:

• Condition monitoring: Detecting failing equipment at an early stage. Failing assets consume up to 30% more energy over an extended period of time.
• Right sizing electrical motors: Electric motors are most efficient when running between 45% and 100% of rated power. At lower loads, much energy is wasted.
• System-level monitoring (e.g. leakage reduction in compressed air systems, piping optimization): Especially in larger systems, health and energy analytics can help to reduce inefficiencies.

• AC motors and rotating equipment

Condition monitoring to detect failing equipment at an early stage

A small pilot, based on data on 375 “low power” assets of less than 45 kW, in a non-rough environment, showed a “relatively low” saving potential of 1.5% for condition monitoring and 2% for system-level monitoring. This is expected to be the lower limit of the saving potential for this study; the expected results for larger assets are much higher.

• Across the board, 5–15% of assets fail each year, with an average of 13%.
• Damage typically goes unnoticed for an average of 6 months.
• During that period, an increase in power consumption of 15-30% is common, which leads to an average energy savings potential of 13% * 22.5% * 6 months = 1.5%.

Second-order energy savings potential related to avoided production losses is not included in these numbers. See also the business case for predictive maintenance.

Rightsizing: Detecting inefficient assets

An average of 10-20% savings in energy consumption is possible.
See also white paper: Using SAM4 to help drive sustainable industry.

Business case examples are available upon request, including case studies in the steel, paper and pulp, and airport industries.

• Energy waste reduction
• Eliminating unplanned downtime and reducing energy consumption

• Reduced downtime costs
• Improved asset reliability
• Increased maintenance efficiency
• Increased worker safety

• Nouryon
• Vopak
• ArcelorMittal
• Schiphol
•  Tata Steel
• BASF
• Sappi